This report summarizes the NIST effort on microfluidic DNA analysis systems for forensic applications sponsored by the National Institute of Justice. Currently emerging microfluidics-based forensic systems are implemented in silica (glass) because the materials and protocols for its use are better understood. The use of plastic-based microfluidics could significantly reduce cost, however, their introduction requires a significant investment in basic research on fabrication and testing protocols. The NIST effort has been focused on developing prototypes in plastic materials that are intended for single use, to lower the cost of testing, reduce the time and manpower required, and reduce contamination. This will enable manufacturing methods and measurement protocols that can be later adopted by companies. The report presents an overview of plastic microfluidic chip design, fabrication, and testing, multichannel separations for forensic applications, and microwave dielectric heating methods for cell lysis and PCR.